PART B

1) Explain Classification of chasis with neat sketch MAY/JUN 2013

1.According to construction
 Ladder chassis
 Back bone chassis
 Monocoque chassis
2.According to control
 Conventional forward chassis
 Semi forward chassis
 Full forward chassis
3. According to fitting to engine
 Engine at front and drive given to rear
 Engine at front and front wheel drive
 Engine at the centre
 Engine at the rear
1.According to construction
Ladder chassis
 Oldest form of chassis
 Used in most SUV
 Has two longitudinal rails interlinked by several cross members.

Back bone chassis

 Has a rectangular tube similar to backbone
 Usually made of glass fiber
 Strong and powerfull for small cars
 Easy to make and cost effective
 Monocoque chassis
 One piece structure that shows the overall vehicle shape
 Manufactured by welding floorpan and otherpiece together
 Cost effective
 Used for robust production
 Used in most of the vehicle

2.According to control
Conventional forward chassis
 Engine fitted in the front of the driver cabin
 Chassis portion cannot be used for carrying passenger and goods

Semi forward chassis

 Half portion of engine is in driver cabin and remaining half is outside the driver cabin
  Chassis used for carrying passenger and goods
 Used in truck

Full forward chassis

 Engine mounted inside the driver cabin
 Driver seat just above the front wheel
 Used in bus chassis

2).List the various types of Frame, ad explain in detail[nov/dec 2011]

 Frame is the main part of the chassis on which remaining part of chassis are mounted
 Frame with stand shocks, twists, stresses, vibration generated during riding
 Frame is narrow at the front for short turning radius
Function
 To carry the load
 To withstand the force, centrifugal force, centrifugal force caused due to sudden braking
Types of frame
 Conventional frame
 Semi integral frame
 Integral frame

Conventional frame
 Non load carrying frame
 The load transferred to suspension by the frame
  Body made of flexible materials like wood and isolated frame by inserting rubber
mounting in between them
 It has two long side membrane and 5 to 6 cross membrane
Semi integral frame
 Half frame is fixed to front end and front suspension is mounted
 It can replaced if met with accident
 Available in all European cars

Integral frame
 The body, shell, under body are welded to single unit
 Underbody is made of floor plates and channel and box section welded to single unit
 This assembly replaces frame
 Decreased weight
 Used in most of the cars
 Cheaper due to less weight
 Repairing is difficult

Section used in frame

 Channel section
 Tubular section
 Box section

Important chassis frame

 Conventional frame
  Tubular space frame
 Monocoque frame
 ULSAB monocoque
 Backbone frame
 Carbon frame
 Aluminum space frame
Conventional frame
Ladder frame

 Simplest and oldest frame

 Consist of two frame not necessary parallel with series of cross membrane
 Offer good beam resistance, poor resistance to torsion
Xframe

 Narrow at the centre

 Offer resistance to high degree of twist
 Heavy front cross member is used to support upper and lower suspension
Perimeter frame
 Middle frame rails sits outboard of the front and rear rails, just behind the rocker
panel/still panels
 Lowers floor plan
 Better safety in the event of side impact
 lower stiffness, due to reduced transition area from front to centre and rear to centre.
 Hence torque boxes and soft suspension used
Tubular space frame
 Employs dozen of cross section tube, position in different direction to provide
mechanical strength
 Tube welded to form complex structure
 Good strength used in sports car

Monocoque frame
 One piece frame
 99% cars are manufactured by this methord
 Done by welding several pieces(spot welding)

ULSAB monocoque
 Ultra Light Steel Auto Body
 Use of hydroform, sandwich steel, laser beam welding
Backbone frame
 A strong tubular backbone chassis connecting the front and rear axle & provide nearly all
mechanical strength
 The whole drivertrain, engine and suspensions are connected to both ends of backbone
 The body usually made of glass fiber
 Good for small sports car only

Carbon frame
 Found in aircraft, superbike, racing car.
 Superior rigidity
 High strength to weight ratio

Aluminum space frame

 Vacuum die cast component and aluminum sections.
 Audi8 is first mass production car featuring aluminum space frame chassis
 Lighter then monocoque frame
3) Explain the various forces acting on the body of automobile and its aerodynamic
effect.[may/june2013]
Purpose of study
 Main aim to reduce drag, wind noise, prevent undesirable lift force.
 To produce downward force to improve traction
 Studied using computer modeling and wind tunnel testing, rolling road.
Vehicle aerodynamics includes three interacting flow fields
Flow past vehicle dynamics
Flow past vehicle dynamics
Flow in passenger compartment
Dynamic characteristic of vehicle
 There are several forces acting on the vehicle while in motion
 Air resistance, grade resistance, rolling resistance, curve resistance
 The effect of these force affect the operation of vehicle is discussed in the section
Aerodynamic resistance
 A vehicle in motion has to overcome the resistance of the air in front of it as well as the
forces due friction acting of the air around it.
 Force proportional to air resistance and is related to the cross section area of the vehicle.
 Aerodynamics resistance is composed of
 Turbulent air flow around the vehicle – 85%
 Friction of air over vehicle body – 12%
Vehicle component resistance ,from radiator andairvent – 3%
Drag force
 Drag is force of air resistance, form of friction
 Drag force is acting in the longitudinal direction
 Drag force has tremendous effect on the way a car accelerates, handles and achieves
better fuel consumption
 Reduce air resistance to improve aerodynamics
 Low drag force- high speed – better fuel consumption.
 Skin friction reduced by using very smooth and polished body.
 Avoid projection to reduce drag
Drag force, D = 0.5*density*drag factor*area* velocity^2
Lift force
Lift force is vertical component of resultant force caused by the pressure on the body
Lift is the force that opposes the weight of an object and raises it into the air
Down force is opposite to lift, the force presses the object towards the ground
Front lift force=0.5*density*coefficient of lift in front *area* velocity^2
Rear lift force=0.5*density*coefficient of lift in rear *area* velocity^2
Cross wind force
 Cross wind force is acting in lateral direction.
 These force Acton the center of pressure instead of centre of gravity.
 Hence cause pitching moment, rolling moment, yawing moment,
Pitching moment:
 This moment is felt in accretion or braking action around horizontal axis of vehicle
 This is caused by drag force or lift force about Y axis, causes real wheel to lift thus
reduce available traction
Rolling moment:
 The moment is felt in cornering, side to side moment around lateral axis
 Caused by cross wind force about X axis
Yawing moment:
 This moment is felt in a spin moment
 Caused by cross wind along Y direction
Rolling resistance:
 Force offer resistance to rolling motion
 Mainly due to friction effect on moving parts and also include friction slip between
payment and tire
Rolling resistance=rolling vehicle coefficient* weight of vehicle
Grade resistance:
 Vehicle move up the grade, a component of the weight of the vehicle acts downward
 Along plane of highways,
 This force act in direction in opposite to that of motion.
Grade resistance= weight * grade resistance
Curve resistance:
  During turning extra force act on the front wheel, this retards the forward motion of the
vehicle
 The sum effect produce a curve resistance, this depends on radius of curve, gross weight
of vehicle
 And velocity of vehicle
Curve resistance= 0.5*((2.15velocity^2*weight)/(gravity*radius))
Traction
Traction is adhesive friction of the tireto the road surface
Driving traction- to accelerate the vehicle
Braking traction- to slow or stop the vehicle
Cornering traction- to turn the vehicle

4) Draw the layout of an automobile and indicate the various component?[may/june 2012]
The main components are
1. Chassis and frame
2. Engine and power plant
3. Transmission system
4. Clutch
5. Final drive
6. Gear box
7. Braking system
8. Steering system
9. Front axle
10. Suspension system

Chassis and frame

 The frame is made of cross frame and side frame, frame is usually made of box, tubular,
and channel section welded and reverted together
In additional to this, it comprises of the spring with the axle and wheel, steering, brakes,
fuel tank exhaust system, radiator, battery and other equipment

Engine and power plant

IC engine- petrol or diesel, 2 stroke or 4 stroke
Engine- cylinder, piston, MPFI in modern cars, fan, fuel, oil pump
Transmission system
Used to transmit power to the wheel
Must provide variable gear ratio, provide reverse gear for heavy vehicle.
Clutch
Used to couple and decouple the engine and transmission.
Final drive(differential gear)
 Finaldrive is the last stage in transferring power from engine to wheel, it reduce the
speed ofPropeller shaft.
 It also turns the drive of propeller shaft by anangle of90degto drive the wheel
 The propeller shaft has a small bevel pinion which meshes with crown wheel
 The crown wheel is connected with cage so that it rotates along crown wheel,
 Small planetary gears freely rotate on the pins of the cage get revolving motion
around large sun gear
 These small planetary gears will revolve around and rotate the large sun gears
connected to rear axles.

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Gear box
Containgear gear arrangement
Braking system
 Used to slow down or stop the vehicle,
 Hydraulic brakes are used in automobiles where brakes are applied by pressure on a fluid
 Mechanical brake is operated by links, levers, etc
 Hand brake or parking brake are mechanical brake to park in slopes.
Steering system
 Front wheel turned left or right using steering mechanism
 Steering wheel is mechanically linked to front wheel to provide steering control
  Primary function is to provide angular motion to front wheel so vehicle can be turned
 Power steering uses pressure of fluid to reduce steering effort
Front axle
 Mounted on the front side
 The front portion weight of vehicle is transmitted to the wheel through axle
 It also takes horizontal and vertical load when vehicle moves on rough road
 It withstand bending and torsional force due to braking
 Usually made of steel drop forging
Suspension system
 Suspension separates the wheel and axle from the body
 Function to isolate the body of the vehicle from shock and vibration generated due to
rough surface, Shock absorber provided for this purpose
 Shock absorber is a form of spring and damper, provided at both front and rear end
 It maintains the stability of vehicle

5). Discus the various vehicle layout based on engine position and drive, discus its
merits and demerits
Engine at front and drive given to rear
 Weight of vehicle well balanced
 Increased efficiency of cooling system
 More space available behind rear seat
Engine at front and front wheel drive

 Low floor space

 Clutch gear box and differential are usually made as single unit thus reduced cost
 lower car centre of gravity
Engine at the centre
 Used in royal tiger world master buses
 Full floor space used effectively

Engine at the rear

 Floor space available since propeller shaft eliminated
 Lower centre of gravity
 Not suitable for hill climb
 Since clutch, gearbox all are made of one unit so repair and maintenance become difficult